Mechanical Technology February 2016

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Heating, cooling, ventilation and air conditioning

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Mechanical Technology — February 2016

echCaL and leading envi-

ronmental solutions provid-

er I-CAT have joined forces

to develop an optimised

evaporation canon using MechCaL’s low

pressure, high flow fans to evaporate

mine water. The companies will work

closely to leverage MechCaL’s techni-

cal leadership in the use of composite

materials with the I-VAP 500’s abil-

ity to perform in harsh environments,

while providing remarkable evaporation

capability.

The aim of this cooperation is to

further the efforts of both companies in

bringing high performance energy efficient

evaporation products to the mining indus-

try. MechCaL’s managing director, Jan du

Plessis predicts that the joint venture will

enable both companies to benefit from a

simpler yet highly effective process for

manufacturing products for the evapora-

tion of excess mine water. “MechCaL

is focused on providing the best min-

ing ventilation and cooling solutions to

help mines achieve high efficiency with

lower energy usage. We expect that our

Fan and evaporation collaboration

optimises energy efficiency

MechCaL and I-CAT

echCaL was established in 2002 to design

and manufacture industrial fans. The com-

pany has developed proprietary software that

allows for high efficiency designs that reduce

emissions by using less energy. Out of

manufacturing facilities in Pretoria, MechCaL

focuses on developing specialised fans made

from advanced composite materials.

I-CAT is a leading environmental manage-

ment company with its primary focus on supply-

ing products and services to assist companies in

environmental compliance. The company deliv-

ers expert services and products through four

main divisions: Dust Solutions, Fire Solutions,

Water Solutions and Environmental Solutions.

MechCaL and I-CAT will work together closely to leverage MechCaL’s technical leadership in

the use of composite materials for fans.

MechCaL has teamed up with l-CAT to

develop a custom-designed evaporator

using one of MechCaL’s patented fan

designs for a high-energy efficient unit

with the first completed units destined

for Douglas Colliery.

collaboration with I-CAT will streamline

the process for our clients by providing

them with a dual solution that is custom

designed as opposed to having to secure

these products separately.”

He adds that MechCal product’s

quality design and manufacturing also in-

crease the product life as well as increas-

ing the mean time before failure while

reducing maintenance requirements.

The two companies have entered into

a memorandum of understanding (MOA)

with I-CAT being designated as the sole

distributor. Six evaporator/fan units were

produced at MechCaL’s manufacturing

facility in Pretoria last year and final as-

sembly of the units with the intelligent

weather control system was undertaken

by I-CAT at its facilities.

The I-CAT I-VAP 500 was originally

developed following the identification of

a need for an effective and environmen-

tally safe evaporation system that can

be used to reduce excess wastewater

in mines. After thorough research and

development done in conjunction with

the environmental department at I-CAT, a

prototype of the I-VAP 500 was designed

and built for trial use.

The I-VAP 500 is capable of handling

500 m

of water per twelve-hour shift

with evaporation rates measured at

between 60% and 65%, depending on

ambient weather conditions. In order to

ensure that the unit is light, durable and

mobile, as well as being resistant to rust,

it must be constructed from composite

materials – the use of which is one of

MechCaL’s areas of expertise.

The high energy efficiency unit will

have an inlet cone and nozzle configura-

tion that is made from composite mate-

rials. The nozzle itself is designed using

CFD coding to assist in an optimum flow

pattern and droplet throw distance. The

MechCaL manufactured I-VAP 500 will

also incorporate MechCaL’s patented

nose and tail cones and state-of-the-art

stator design, which improves air flow

by reducing turbulence and promoting

laminar flow.

The units are designed to be ‘fit-for-

purpose’ with an emphasis on energy,

evaporative efficiency and noise reduc-

tion. Working within harsh environments,

the I-VAP 500 will ultimately manage

excess water through evaporation but

will also be adaptable for use in dust sup-

pression as well as potential fire fighting

applications by changing the water nozzle

and pump configuration.

In commenting on the future relation-

ship with I-CAT, Du Plessis says: “I-CAT

is a prime example of an innovative com-

pany that seeks continuous improvement

in environmental applications and thus

the innovative nature of our two compa-

nies is a hand in glove fit.”